Michael Geller1, Britney McCoy1, Arman Tanman1, Dennis Johnson1

Imad Khalek2, Kent Spreen2

2012 Directions in Engine-Efficiency and Emissions Research (DEER) Conference

October 19, 2012

Characterizing Test Methods and Emissions Reduction Performance of In-Use Diesel Retrofit

Technologies from the National Clean Diesel Campaign

1U.S.EPA, Office of Transportation and Air Quality, 1200 Pennsylvania Avenue, Washington, DC 20460 2Southwest Research Institute, 6220 Culebra Rd., San Antonio, Texas 78238

1

Overview • Introduction

• In-Use Test Objectives

• Test Methods

• Retrofit Emission Reduction Performance

• Conclusions

2

EPA’s Priorities

• Protecting public health and the environment • Improving air quality • Reducing exposure to pollutants • Reducing diesel engine emissions

– HC, CO, NOx, CO2, toxics – Particulate Matter (PM)

3

Clean Diesel Technology Assessment Center

• Comprehensive approach to reducing emissions (criteria and GHG) from HD fleets.

• Verification of Retrofit Technologies – Verify emission and fuel-saving technologies to inform the

market and support incentive programs

• Protocol Development • In-Use Performance and Testing

– Research, test and evaluate emission reduction and fuel-saving technologies and strategies – EPA In-Use Testing

4

Testing Objectives

• Evaluate test methods and protocols • Explore improvements to the verification process • Filling gaps – addressing new sectors/technologies • Increase confidence that technologies perform as

expected • Assess real-world durability

5

Test Methods • Engine Dynamometer Testing

• 40 CFR Part 86 and Part 1065 • Transient FTP cycles, 1 cold + 3 hot starts • Criteria pollutants, PAH sampling, EC/OC, PM number size

distributions

• Chassis Dynamometer Testing • Test Cycles: Heavy-Heavy Duty Diesel Truck (HHDDT)

Cycle; City Suburban Cycle (CSC) • Criteria pollutants and fuel economy

• Smoke Opacity Testing • SAE 1667 • Snap acceleration smoke testing using 3 different meters 6

Test Engines Engine Manufacturer

Navistar

Engine Model T444E B190

Model Year 1999

Displacement 7.3 liter

Cylinder Configuration

V-8

Rated Power 190 hp @ 2300 rpm

Cummins Caterpillar (chassis test)

ISB 215 3126

1999 2002

5.9 liter 7.2 liter

Inline 6 Inline 6

215 hp @ 2700 rpm

210 hp @ 2400 rpm

7

Test Devices

8

• Source application: School Bus • Location of source fleets: School districts

across the U.S., including Pennsylvania, Maryland, Texas and California

• Retrofits originally funded with EPA DERA grants

• DOCs and DPFs

9 Diagram of Test Set-Up, Source: SwRI

Test Method Evaluation

10

• 40CFR Part 86 and Part 1065 • Legacy engines certified using Part 86 • Evolution of PM sampling filter media

– T60A20, Fluorocarbon coated glass fiber filter – TX40, PTFE bonded glass microfiber filter – Teflon Membrane

• Engine exhaust PM characteristics – Organic carbon fraction of PM varies between engines

DOC Test Method Evaluation

Device Filter Media PM HC CO SOF

DOC#1 T60A20 20% 76% 63% 29%

DOC#2 T60A20 16% 81% 66% 29%

DOC#3 T60A20 20% 70% 37% 29%

DOC#3 TX40 13% 95% 41% 24%

DOC#4 TX40 11% 95% 41% 24%

11

PAH Reduction Efficiency: DOCs

0%10%20%30%40%50%60%70%80%90%

100%Baseline DOC-03 DOC-02

0%10%20%30%40%50%60%70%80%90%

100%Baseline DOC-03 DOC-04 DOC-05

12

~85%

~85%

City Suburban Cycle Heavy-Heavy Duty Diesel Truck Cycle

Chassis Dynamometer Test Cycles

13

Developed by CARB Developed by WVU

Chassis Dynamometer Results

Level of Emissions Reduction

Devices HC CO NOx PM CO2 Drive Cycle

DPF6C 90% 98% 6% 95% 1% HHDDT

95% 99% 6% 98% 1% CSC

DPF7C 91% 97% -5% 94% -1% HHDDT

85% 92% 3% 98% -1% CSC

14

EPA Tested Levels of Reduction: DPFs DPF Name Label Date Tested PM In-Use PM Verified

DPF1 DPF 2007-2008 95% 90% DPF2A Bus 940 Nov 2008 64% 85% DPF3A Bus 941 Nov 2008 65% 85% DPF4B Bus 124 Nov 2008 51% 60%

DPF5B Bus 134 Nov 2008 82% 60%

DPF6C Bus 2037 July 2012 97% 90%

DPF7C Bus 2010 July 2012 98% 90%

DPF8A Bus 48 July 2012 97% 85%

DPF9A Bus 46 July 2012 99% 85%

15 Notes: All devices met the 75% threshold necessary to demonstrate a passing in-use device DPFs that share the same letter at end of name share the same make/model

Particle Number Reduction

0.0E+005.0E+121.0E+131.5E+132.0E+132.5E+133.0E+133.5E+134.0E+134.5E+135.0E+13

1 10 100 1000

Bra

ke S

peci

fic N

umbe

r Em

issi

on

[Par

t./hp

.h]

Diameter [nm]

184-H1 155-H1 170-H1 198-H1 218-H1

1 10 100 1000

Axis

Titl

e

Diameter [nm]

A_0581_492_H1 A_0581_466_H1

A_0581_482_H1 Baseline_H1

DPFs DOCs

16 *Each line represents one device.

Engine Out

EC-OC Reduction Efficiency

0

20

40

60

80

100

120

168-C 17-H 182-C 18-H 196-C 19-H 216-C 21-H

Effic

ienc

y [%

]

HC W/O filterCorr

HC W filter Corr

EC

Total PM W/Ofilter Corr

Total PM Wfilter Corr

Filter based

DPFs DOCs

DOC02_C DOC02_H DOC03_C DOC03_H 17

Smoke Opacity Results

– Absolute opacity values depend on type of meter

R² ≈ 0.95

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Opa

city

(%)

PM Removal Efficiency (%)

Telonic Average

Red Mountain Average

CalTest 1000 Average

18

Summary and Conclusions • Evaluation of in-use DPFs shows levels of reduction within in-

use testing objectives – Most recent DPF testing showed PM emission reductions > 90% – Reduce elemental/black carbon by ~99% – DPFs have proven durable in retrofit applications

• DOCs reduce PAHs and other toxic air contaminants – Cost effective retrofits for applications not suitable for DPFs

• Opacity testing needs further investigation but has the potential for use as a screening tool for DPF performance

• Test methods used for verification are appropriate for determining retrofit efficiency

19

Acknowledgements • Montgomery County School District

– Todd Watkins, Michael Vernon, Larry Riner

• Dripping Springs Independent School District – Pam Swanks, Bryce Sheppard

• Engine Control Systems – Kevin Brown, Campbell McConnell

• Donaldson Company,Inc. – Julian Imes, Todd Taubert

• California Air Resources Board – John Karim, George Gatt

20

Thank you

geller.michael@epa.gov

21